Abstract
The present paper proposes a methodology to design and manufacture optimized turbomachinery components by leveraging the potential of Topology Optimization (TO) and Additive Manufacturing (AM). The method envisages the use of TO to define the best configuration of the rotoric components in terms of both static and dynamic behavior with a resultant reduction of overall weight. Eventually, the topology-optimized component is manufactured by using appropriate materials that can guarantee valid mechanical performances. The proposed strategy has been applied to a 2D impeller used for centrifugal compressors to prove the effectiveness of a TO+AM-based approach. Although this approach has never been extensively used before to centrifugal compressors and expanders, its application on rotor and stator components might unlock several benefits: tuning the natural frequencies, a reduction in the stress level, and a lighter weight of the rotating part. These objectives can be reached alone or in combination, performing a single analysis or a multiple analyses optimization. Finally, the introduction of AM technologies as standard manufacturing resources could bring sensible benefits with respect to the time to production and availability of components. Such aspects are essential in the Oil and Gas context, when dealing with new projects but also for service operations.
Highlights
The increasing requirement for energy demands for highly efficient turbomachinery systems [1]
Based on the above-mentioned considerations, the present paper proposes a unified approach for designing and manufacturing optimized turbomachinery components by leveraging the potential of Topology Optimization (TO) and Additive Manufacturing (AM)
Some constraints, detailed in the text to follow, are taken into account with the aim of manufacturing efficient impellers: (i) the material used for the component that should guarantee the following properties: high ductility at different operating temperature; (ii) corrosion resistance induced by the presence of water and CO2 and in presence of H2S; (iii) pitting resistance induced by the presence of chlorides; (iv) high strength to sustain the working condition; (v) market availability of the material, in order to keep low supply times and cost
Summary
The increasing requirement for energy demands for highly efficient turbomachinery systems [1]. Modern design software allows shape optimizations in a relative short time, leading to complex geometries unconstrained from conventional mathematical surfaces In this context, Topology Optimization (TO) software systems are among the most used design tools. Metal AM processes are an established alternative to traditional subtractive ones even for the fabrication of mechanical parts that need to sustain significant structural loads. A design method was applied to a turbine disk to obtain a safe range, without resonance conditions, around the frequency of the external loads and to reduce the weight Beyond such pilot cases, to the best of authors’ knowledge, this work is among the first ones dealing with a complete design of a TO/AM rotoric part. The design of structurally efficient shapes can lead, in turn, to a weight reduction of the parts, with a consequent abatement of costs
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